Systems and methods for providing heat to articles using heated formable media

ABSTRACT

Systems and methods for providing heat to a three-dimensional article are disclosed. The method can include inserting at least a portion of the article over a form. The method can further include inserting the form and article at least partially within an article container and moving the form and article into engagement with a flexible membrane where the membrane and the article container form an airtight chamber. The method can further include exposing the airtight chamber to a pressure less than atmospheric pressure to pull the membrane against at least a portion of the article and exposing the membrane to a heated deformable media.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent App. No.63/148,983, filed Feb. 12, 2021, and titled “Systems and Methods forProviding Heat to Articles Using Heated Formable Media” and to U.S.Provisional Patent App. No. 63/239,707, filed Sep. 1, 2021, and titled“Systems and Methods for Providing Heat to Articles Using HeatedFormable Media”. These applications are assigned to the same entity asthe present application, and are incorporated herein by reference in theentirety.

TECHNICAL FIELD

The present disclosure is directed to a system and methods for providingheat to articles, such as thermocoupling an article shape or attachingan element to an article.

BACKGROUND

Heat can be provided to certain articles, such as knit articles havingthermo-fuse-able yarns, to form the article to a desired shape.Attaching an element to an article can include heating a thermo-adhesiveto couple an element to an article.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Illustrative aspects of the present invention are described in detailbelow with reference to the attached drawing figures, which areincorporated by reference herein and wherein:

FIG. 1 depicts a perspective view of a system for providing heat to anarticle, in accordance with aspects hereof;

FIG. 1A depicts a perspective view similar to FIG. 1 but with an articleand an element in place, and guard panels removed to show details ofconstruction, in accordance with aspects hereof;

FIG. 1B depicts an enlarged view of the encircled region 1B shown inFIG. 1A, in accordance with aspects hereof;

FIG. 2 depicts a perspective view similar to FIG. 1A but with an articlecontainer moved forward, and with further guard panels removed to showdetails of construction, in accordance with aspects hereof;

FIG. 3 depicts a cross-section taken along line 3-3 of FIG. 2 , but withthe guard panels in place, in accordance with aspects hereof;

FIG. 4 depicts a perspective view similar to FIG. 2 , but with thearticle container raised, in accordance with aspects hereof;

FIG. 5 depicts a cross-section taken along line 5-5 of FIG. 4 , but withthe guard panels in place, in accordance with aspects hereof;

FIG. 6 depicts an enlarged view of the encircled region 6 of FIG. 5 , inaccordance with aspects hereof;

FIG. 7 depicts a view similar to FIG. 6 , but with a vacuum applied, inaccordance with aspects hereof;

FIG. 8 depicts a view similar to FIG. 7 , but with a heated mediareleased from a first chamber to a second chamber, in accordance withaspects hereof;

FIG. 9A depicts a perspective view similar to FIG. 2 , in accordancewith aspects hereof;

FIG. 9B depicts a perspective view similar to FIG. 9A, but with thearticle container moved rearwardly and a media container rotated, inaccordance with aspects hereof;

FIG. 9C depicts a perspective view similar to FIG. 9B, but with themedia container rotated to another position, in accordance with aspectshereof;

FIG. 10A depicts an enlarged perspective view of the media container, inaccordance with aspects hereof;

FIG. 10B depicts a view similar to FIG. 10A but with the media containerin a different orientation, in accordance with aspects hereof;

FIG. 10C depicts a view similar to FIG. 10B, but with a rack moved to aposition to open internal gates of the media container, in accordancewith aspects hereof;

FIG. 11 is a cross-section of the media container taken along line 11-11of FIG. 10A;

FIG. 12 is a cross-section taken along line 12-12 of FIG. 9A;

FIG. 13 is a flow diagram of a method of attaching an article to anelement, in accordance with aspects hereof;

FIG. 14 is a perspective view of another aspect of a system forproviding heat to an article, in accordance with aspects hereof;

FIG. 15 is a cross-sectional view of the system of FIG. 14 , shown withthe media container in an unloading position;

FIG. 16 is a view similar to FIG. 15 , shown with the media container inposition over the article container;

FIG. 17 is a view similar to FIG. 16 , shown with the duct deliveringhot media to the media container;

FIG. 18 is a view similar to FIG. 15 , showing the media beingtransferred from the media container to the return bucket;

FIG. 19 is a view similar to FIG. 18 , shown with the return bucket inthe raised position;

FIG. 20 is a view similar to FIG. 19 , shown with the return bucketpivoted to deliver media to the heated media chamber;

FIG. 21 is an enlarged view of the encircled region 21 in FIG. 15 ;

FIG. 22 is an enlarged view of the encircled region 22 in FIG. 15 ;

FIG. 23 is an enlarged view of the article and element in place withinthe article container;

FIG. 24 is an enlarged view of the heated media chamber, showing theaccess door and piston;

FIG. 25 is a cross-sectional view of the heated media chamber;

FIG. 26 is a cross-section view of an alternative aspect of a system forproviding heat to an article, in accordance with aspects hereof;

FIG. 27 is a perspective view of an alternative aspect of a system forproviding heat to an article, in accordance with aspects hereof; and

FIG. 28 is a schematic view showing the stations of FIG. 27 .

DETAILED DESCRIPTION

The subject matter of aspects of the present invention is described withspecificity herein to meet statutory requirements. However, thedescription itself is not intended to limit the scope of this patent.Rather, the inventors have contemplated that the claimed subject mattermight also be embodied in other ways, to include different steps orcombinations of steps similar to the ones described in this document, inconjunction with other present or future technologies.

Aspects herein are directed to methods and systems for providing heat toarticles and/or for coupling elements to articles. In some aspects,methods and systems are directed to attaching an element to an article.Certain attaching systems can include heating an element and an articlewith heating lamps to re-activate cements or other thermo-adhesives.These lamps generate high temperatures that can limit the types ofelements and articles to be joined. In addition, these systems andmethods are often labor-intensive, and result in poor consistency interms of quality and performance.

The systems and methods disclosed herein can alleviate one or more ofthe above-mentioned problems. At a high level, the methods disclosedherein can aid in coupling an element to a three-dimensional article,such as a footwear upper. The method can include inserting at least aportion of the article over a form, and placing the element on thearticle in a desired location. The method can further include insertingthe form, article and element at least partially within an articlecontainer and moving the form, article and element into engagement witha flexible membrane where the membrane and the article container form anairtight chamber. The method can further include exposing the airtightchamber to a pressure less than atmospheric pressure to pull themembrane against at least a portion of the article and the element andexposing the membrane to a heated deformable media.

In another aspect, a system for providing heat to a three-dimensionalarticle is provided. The system may include an article container havingan interior volume, and at least one open face. The system may alsoinclude a form selectively held at least partially within the articlecontainer. The form may have a shape at least partially corresponding tothe three-dimensional article, and adapted to hold the three-dimensionalarticle. The system may also include a media container having a firstchamber and a second chamber that are separated by a selectivelyopenable valve. The system may have a flexible membrane extending atleast partially across a face of the second chamber of the mediacontainer. A deformable media may be held within the media container;the deformable media being held within the first chamber in a firstcondition when the selectively openable valve is in a closed position,and the deformable media being allowed to enter the second chamber whenthe selectively openable valve is in an open position. The system mayalso include at least one heating element positioned to heat thedeformable media when the deformable media is in the first chamber ofthe media container. The system may also include an engagement mechanismcoupled to the article container and adapted to move the articlecontainer such that the form having the three-dimensional article andthe element are moved into engagement with the flexible membrane on themedia container. The deformable media can be heated by the at least oneheating element when the deformable media is in the first chamber andthe heated deformable media is allowed to enter the second chamber byopening the selectively openable valve. This allows the deformable mediato surround the flexible membrane.

In yet another aspect, a method for providing heat to an article isprovided. The method can include inserting at least a portion of thearticle over a form. The method can further include inserting the formand article at least partially within an article container and movingthe form and article into engagement with a flexible membrane. Themethod can further include exposing the membrane to a heated deformablemedia.

Turning now to the figures, FIG. 1 depicts a system 10 for providingheat to an article 14. In some aspects, the system 10 can be used tothermo-couple or attach an element 12 to an article 14 (as best seen inFIG. 1B). In some aspects, the article 14 is an article of footwear,such as an upper. In some aspects, the article 14 is a three-dimensionalupper made of a fabric, and in some aspects, the fabric is a woven, knitor braided material. It should be understood, that while the system 10depicts the article 14 as a portion of an article of footwear, e.g., anupper, other types of articles or other portions of an article offootwear can be utilized in the system 10 described herein. In someaspects, the system 10 is used to provide the article 14 with athree-dimensional shape by providing heat to the article 14. In someaspects, the article 14 may be constructed from thermo-fuse-ablematerials, such as knit yarns have a desired melting temperature. Insome aspects, the element 12 is an accompanying part of a footwearupper, and in some aspects is a heel counter. It should be understoodthat element 12 could be any of a number of different elements coupledto the article 14, e.g. a midsole, an outsole, aesthetic embellishments,a toe support, a foxing strip or other footwear elements. In someaspects, the article 14 and/or the element 12 are of a thermoformable orthermoplastic material, or have a layer of thermoformable or thermallyactivated material thereon, that, when heated, forms the article 14 intoa desired three-dimensional shape and/or bonds or attaches the article14 to the element 12.

In some aspects, the system 10 has an outer supportive frame 16. In someaspects, the frame 16 is made from square metal tubing, but could alsobe any of a number of rigid materials. The frame 16 can be supported ona surface with a plurality of feet 18. As best seen in FIG. 3 , theframe includes a lower portion 20 and an upper portion 22, separated byan upper plate 24. The lower portion 20 supports a lower plate 26 thatin turn supports a vacuum tank 28. The upper plate 24 and the lowerplate 26, in some aspects, are made of rigid materials, such as a metal.The lower portion 20 can be enclosed with outer guard panels 30 toprevent access to the internal components of the lower portion 20.

As seen in FIG. 12 , the lower portion 20 also includes a cross-support32 rigidly secured to the frame 16, extending from one end of the frame16 to the other end of the frame 16. The cross-support 32 supports alinear actuator 34. In some aspects, the linear actuator 34 is arod-less pneumatic cylinder, but it should be understood that the linearactuator 36 could be any of a number of devices to effect lineartranslation. The linear actuator 34 moves a bracket 36 along the lengthof the linear actuator 34. It should be understood that, while notshown, the actuator 34 is coupled to a power source, such as acompressed air supply, or electricity to effect movement of the bracket36. The bracket 36 is also coupled to a vacuum slide plate 38. Thevacuum slide plate 38 moves with the bracket 36, and is also supportedon each side by a linear guide 40. The linear guides 40 allow the vacuumslide plate 38 to translate along the path of the linear actuator 34.The vacuum slide plate 38 also supports an article container 42. Throughthe activation of the linear actuator 34, the article container 42 istranslated from a loading position, as shown in FIG. 1A, to a forwardposition, as shown in FIG. 2 .

The article container 42 is best seen in FIGS. 3 and 12 . The articlecontainer 42 has a base 44 that supports a tank 46 and a lid 48. Thebase 44, the tank 46 and the lid 48 define an internal volume. As shownin FIG. 1B, the lid 48 has an opening 49 that allows access to theinternal volume, where the lid 48 and opening 49 form an open face ofthe article container 42. In some aspects, as shown in FIG. 3 , thearticle container 42 has a bracket 50 that is used to selectively couplea form 52 to the article container 42. In some aspects, the bracket 50has extending pins, and the form 52 has holes corresponding to the pins,to removably attach the form 52 to the bracket 50. In some aspects, whenthe form 52 is coupled to the bracket 50, a portion of the form 52extends beyond the lid 48, with a portion of the form 52 extending intothe internal volume of the article container 42. In some aspects, theform 52 is in the shape of an article of footwear, such as a footwearupper. In some aspects, the form 52 is a footwear last. Vacuum tubing(not shown) extends from the vacuum tank 28 to the article container 42to pull negative pressure (a vacuum) on the internal volume of thearticle container, as is further described below. In some aspects, theform 52 is shaped to at least partially correspond to the shape of thearticle 14. In operation, the article 14 can be oriented on the form 52,and held on the form 52. In some aspects, the article 14 is held on theform 52 along with the element 12, and the assembly of the form 52,article 14 and element 12 can be coupled to the bracket 50, as isfurther described below. While only one form 52 is shown, in someaspects, the system 10 could be modified to operate with multiplestations of article containers 42, having one or multiple forms 52 perstation. As best seen in FIG. 3 , the base 44 of the article container42 extends outwardly beyond the perimeter of the tank 46. This extendingportion of the base 44 supports a pair of bushings 54. Each bushing 54surrounds a column 56 that is coupled to the vacuum slide plate 38. Thecolumns 56 extend upwardly from the base 44, and, together with thebushings 54, guide the article container 42 in vertical movement. Insome aspects, the bushings 54 are bearings. To effect vertical movementof the article container 42, an actuator 58 is provided. In someaspects, the body of the actuator 58 is coupled to the underside of thevacuum slide plate 38. The actuator 58 also has an extending rod 60, theouter end of which is coupled to the base 44 of article container 42. Insome aspects, the actuator 58 can be any of a number of different linearactuators, including, but not limited to, pneumatic cylinders, electriclinear actuators or other types of linear drive systems. The actuator 58selectively moves the article container 42 from a lower position, asshown in FIGS. 2 and 3 , to a raised position, as shown in FIGS. 4 and 5, guided by bushings 54 and columns 56. It should be understood that,while not shown, the actuator 58 is coupled to a power source, such as acompressed air supply, or electricity to effect movement of the rod 60and thus the article container 42.

As best seen in FIGS. 2 and 12 , the upper plate 26 has an openingtherein that allows movement of the article container 42. A pair ofbrackets 62 are coupled to the upper plate 26 and extend upwardlytherefrom. Each bracket 62 is made from a rigid, sturdy material, suchas metal, and may have a reinforcing buttress 64 to provide additionalstrength and rigidity. One bracket 62 supports a motor 66 and in someaspects, a reducer 68. The motor 66 provides rotational output toselectively rotate a flange 70. The end of the flange 70 opposite themotor 66 is fixedly coupled to a media container 72. The opposite sideof the media container 72 is also rotationally supported by anadditional flange 74 that extends through the bracket 62. In someaspects, a bushing 76 is used to surround the flange 74, extending fromthe connection to the media container 72 to the bracket 62. As isfurther described below, the media container 72 is rotationallysupported on the brackets 62 by the flange 70 and the flange 74. Themedia container 72 can be selectively rotated by activating motor 66,the importance of which is described below. While not shown, the motor66 is coupled to an electrical power source.

As best seen in FIG. 11 , the media container 72 has an outer body 78, acover 80 and a base 82. In some aspects, the external faces of outerbody 78 may include external insulation panels 84, as best seen in FIG.11 . In some aspects, interior of panels 84, each side of the mediacontainer 72 may include a further insulation layer 86 and an interiorplate 88. In some aspects, the base 82 surrounds a series of layers,including a first insulation layer 90, a second insulation layer 92, aninternal cover 94 and a base gasket 96. In some aspects, the base gasket96 is held between the internal cover 94 and a base frame 98 around theperimeter of the outer body 78, and between the internal cover 94 andthe interior insulation layer 86.

On the other end of media container 72, the cover 80 includes anexternal insulation panel 100 that is similar to external insulationpanels 84. The external insulation panel 100 surrounds a frame 102 thatdefines an opening shaped and sized to receive at least a portion of theassembly of the element 12, article 14 and the form 52. A gasket 104forms a perimeter surrounding the opening in the frame 102. The gasket104 selectively forms a seal with article container 42 when articlecontainer 42 is moved to a raised position as is further describedbelow. As best seen in FIG. 11 , a perimeter of a flexible membrane 106is held between the frame 102 and an internal plate 108. The membrane106 has a portion 110 that extends into the media container 72. In someaspects, the portion 110 is shaped to generally correspond to theportion of the form 52 that extends beyond the article container 42. Insome aspects, the flexible membrane 106 is a silicon material with athickness in the range of 1.4-1.6 millimeters. It should be understoodthat other flexible, heat resistant materials could also be used, andthat other thickness ranges are contemplated. In some aspects, anadditional insulation panel 112 is disposed over the internal plate 108and an internal plate 114 is disposed over the insulation panel 112. Insome aspects, both the insulation panel 112 and the internal plate 114have openings that correspond to the opening in the frame 102.

As best seen in FIG. 11 , the interior plates 88, internal cover 94,internal plate 114 and a portion of the membrane 106 from an interiorvolume within the media container 72. This interior volume is separatedinto a first chamber 116 and a second chamber 118 by a valve 120. Insome aspects, the valve 120 includes a pair of gates 122 (see FIGS. 11and 12 ) that are moved in a coordinated fashion. Each gate 122 has awidth that is half the width of the interior volume, such that,together, the gates 122 span the width of the interior volume when in aclosed position. In the closed position, the gates 122 separate thefirst chamber 116 from the second chamber 118. Each gate 122 is coupledto a shaft 124 that extends through the media container 72. As best seenin FIG. 11 , a valve spacer 126 surrounds the shaft 124 proximate theinternal plate 88. The shaft 124 extends through the side of the mediacontainer 72 and in some aspects, is rotationally supported by abushing. In some aspects, the bushings include a bearing to facilitatesmooth rotational movement. As seen in FIG. 10A, on the exterior of themedia container 72, in some aspects, a first gear 130 is coupled to oneof the shafts 124 and a second gear 132 is coupled to the other of theshafts 124. In some aspects, the first gear 130 has teeth that mesh withteeth on the second gear 132, such that rotation of the first gear 130in one direction effects rotation of the second gear 132 in the seconddirection. In some aspects, a rack 134 is driven linearly by a compactactuator 136. The rack 134 has teeth that interact with the first gear130, such that linear motion of the rack 134 effects rotational motionof the first gear 130, and in turn, the second gear 132. The actuator136 can be any of a number of actuators, such as electric or pneumaticactuators, that effect linear movement of the rack 134. As the actuator136 moves the rack 134, the first gear 130 rotates in a first directionand causes the second gear 132 to rotate in an opposite direction. Asthe first gear 130 and the second gear 132 rotate, they in turn causethe respective shaft 124 to which they are coupled to rotate as well,and thus cause the respective gate 122 coupled to the shaft 124 torotate. The gates 122 form the selectively openable valve 120. In afirst position, the gates 122 are horizontally disposed across theinterior volume of the media container 72 to separate the first chamber116 from the second chamber 118. In a second position, the gates 122 arerotated (by the actuator 136, the rack 134, the first gear 130, thesecond gear 132 and the shafts 124) to a more vertical position,allowing access between the first chamber 116 and the second chamber118.

In some aspects, as best seen in FIG. 11 , a plurality of heatingelements 140 are coupled to the media container 72 and extend throughand across the interior volume of the first chamber 116 of the mediacontainer. In some aspects, the heating elements 140 are cylindricalresistance heating elements. In some aspects, the heating elements 140are surrounded by a protective cover 142, at least within the interiorvolume of the first chamber 116. The media container 72 holds a volumeof formable media 142 that takes the shape of the media container 72 andthat flows in and around the heating elements 140 when the media 142 isin the first chamber 116, (see FIG. 6 ) and that flows on and around themembrane 106 when the media 142 is in the second chamber 118. In someaspects, the media 142 is sand, but it should be understood that otherformable media having thermal retention properties could also be used,such as ceramic microspheres, glass microspheres, corundum or othermaterials. For clarity, the formable media 142 is not shown in everyfigure.

As best seen in FIG. 1 , in some aspects, the system 10 includes aplurality of guard panels 150 supported by an upper frame 152 thatprevent access to the media container 72, and the article container 42when the article container 42 is in the forward position. As shown inFIG. 1 , in some aspects, the system 10 includes a control panel 154.The control panel 154 houses the electronic logic that controls theoperation of system 10. In some aspects, this includes controlling theoperation of the vacuum tank 28, the linear actuator 34, the actuator58, the motor 66, the compact actuator 136 and the heating elements 140.The logic within the control panel executes commands to carry out themethod described below with respect to FIG. 13 .

In use, in some aspects, an operator may place the article 14 onto theform 52 (and one or more elements 12 if desired). In some aspects, asshown in method 160 of FIG. 13 , the article 14 may be placed on theform 52, as shown at block 162. The operator may place element 12 in thedesired location on article 14, either before or after placing thearticle 14 on the form 52, as shown at block 164. In some aspects, thearticle 14 is solely placed on the form 52, such as when the system 10is used to form the shape of article 14 by providing heat to the article14. With the article container 42 in the loading position, as shown inFIG. 1 , the operator may place the form 52 (with the article 14 and/orelement(s) 12 in place) onto the bracket 50 within article container 42,as shown at block 166. The article 14, element 12 and the form 52 areshown in place on bracket 50 in the loading position in FIGS. 1A and 1B.In this position, the formable media 142 is in the first chamber 116 ofthe media container 72. While in the first chamber 116, the formablemedia 142 is heated to a desired temperature by the heating elements140. In some aspects, the formable media 142 is heated to a range ofbetween 230-250 degrees Celsius. It should be understood that thetemperature range is dependent upon the formable media 142 as well asthe materials to be thermoformed or attached (such as the article 14 andany elements 12). Once loaded in the article container 42, the linearactuator 34 may be engaged to move the vacuum slide plate 38 and articlecontainer 42 forward along linear guides 42 to the forward position asshown in FIGS. 2 and 3 . With article container 42 in the forwardposition, the motor 66 is used to rotate the media container 72 suchthat the first chamber 116 is directly above the second chamber 118 asshown in FIGS. 2 and 6 , for example. The media container 72 can berotated to this position either before, during or after articlecontainer 42 is moved to the forward position as shown in FIG. 2 . FIG.10B shows the media container 72 in isolation in this position. In thisposition, the form 52 (with the article 14 and/or element 12) is invertical alignment with the interior portion 110 of membrane 106. Oncealigned, the linear actuator 58 acts as an engagement mechanism andmoves rod 60 and raises the base 44 and thus the article container 42,guided by bushings 54 along columns 56. The linear actuator 58(engagement mechanism) raises the article container 42 into engagementwith the media container 72, as shown at block 168, and as seen in FIGS.4 and 5 . In some aspects, the gasket 104 on media container 72 forms anairtight seal with the lid 48 of the article container 42. In thisposition, the vacuum tank 28 pulls a negative pressure within the volumewithin the tank 46 of article container 42, sealed with the gasket 104and the membrane 106, as shown at block 170. In some aspects, the vacuumtank 28 pulls a negative pressure, and in some aspects the vacuum tankeffects a pressure of negative 1 (−1) bar. This negative pressure pullsthe membrane 106 against the form 52, with the article 14 and/or element12 between the form 52 and the membrane 106. FIG. 6 shows the membrane106 spaced from the form 52, the article 14 and the element 12 before avacuum is applied by the vacuum tank 28. FIG. 7 shows the membrane 106pulled tight and sandwiching the article 14 and the element 12 betweenthe form 52 and the membrane 106. With the vacuum applied, the actuator136 is engaged to move the rack 134 to the position shown in FIG. 8 andthus rotating the first gear 130 and the second gear 132. This rotationin turn rotates the gates 122, allowing the heated, formable media 142to flow from the first chamber 116 to the second chamber 118 as shown inFIG. 8 . The formable media 142 surrounds the membrane 106 and thus thearticle 14 and element 12, as shown at block 172. The heat from theformable media 142 is transferred through the membrane 106 and to thearticle 14 and/or the element 12 thus activating any thermo-adhesives onthe article 14 and/or element 12, or to form the article 14 into adesired shape. In certain aspects, the heated formable media 142transfer heat over time to the article 14 and/or element 12 sufficientto cause at least a portion of a material of the article 14 and/or theelement 12 to melt and/or deform. In some aspects, the heated formablemedia 142 is left in position over the membrane 106 for a period ofbetween ten and forty seconds, or for a time period of between twentyand thirty seconds. In some aspects, a time period of twenty-fiveseconds is used. In some aspects, the heating elements 140 initiallyheat the formable media 142 to a temperature range of between 150° C. toabout 350° C., or about 200° C. to about 300° C., or about 230° C. toabout 250° C. In some aspects, thermo-couples may be used to determine adesired temperature range for deformable media 142. In addition, theduration of exposure of the article 14 and element 12 to the heatedformable media 142 may be adjusted to obtain a proper bonding orattaching of the article 14 and the element 12. After the desired timedelay, the vacuum tank 28 releases the negative pressure and theactuator 58 is used to lower the article container 42 as shown in FIG.9A. The actuator 34 is used to return the article container 42 from theforward position to the loading position as shown in FIG. 9B, and theoperator may remove the form 52 and the now-coupled article 14 andelement 12. At this point, the article 14 is formed into the desiredshape or the article 14 and element 12 are bonded, thermo-coupled orattached to one another. To ready system 10 for an additional cycle, themotor 66 is used to rotate the media container 72 so that the firstchamber 116 is below the second chamber 118 as shown in FIG. 9B (FIG.10A shows the media container 72 in isolation in this position). At thispoint, the gates 122 are still rotated to an open position, allowing theformable media 142 to flow from the second chamber 118 back into thefirst chamber 116. After a time delay allowing the formable media 142 toflow from the second chamber 118 to the first chamber 116, the actuator136 is engaged to move the rack 134, rotating the first gear 130 and thesecond gear 132, to close the gates 122. In some aspects, the motor 66rotates the media container 72 past vertical (as shown in FIG. 9C andFIG. 10C) and then back to vertical (FIG. 9A and FIG. 10B), to betterdistribute and level the formable media 142 within the media container72.

It should be understood that any number of articles 14 may be shaped,and/or articles 14 and elements 12 may be attached by system 10, andthat the article 14 and the element 12 are shown as examples within theFigures, but that other components, shapes and sizes of both article 14and element 12 are contemplated. Moreover, while the system 10 isdepicted as a stand-alone system, a larger system, with multiple articlecontainers 42 and media container 72 may be used and integrated into alarger automated system, such as a rotary system where different articlecontainers 42 are loaded at different times.

In one aspect, the article 14 and/or the element 12 can include amaterial, or a layer, that may fuse with corresponding portionsthroughout the attaching process. In such an aspect, the element 12, thearticle 14 and/or a layer thereof, can include a thermoplastic materialthat has a melting temperature, a Vicat softening temperature, a heatdeflection temperature, or any combination thereof, in the range ofabout 80° C. to about 135° C., or from about 90° C. to about 120° C. Themelting temperature can be determined according to the test methoddetailed in ASTM D7138-16. The Vicat softening temperature can bedetermined according to the test method detailed in ASTM D1525-09,preferably using Load A and Rate A. The heat deflection temperature canbe determined according to the test method detailed in ASTM D648-16,using a 0.455 MPa applied stress.

In aspects, the article 14 can be a component of an article of footwear,such as an upper. The upper can include a woven, braided, knit, ornon-woven textile. In aspects, such a textile may include one or moreyarns or fibers comprising a yarn or fiber composition that includes athermoplastic material. In such aspects, the thermoplastic materialand/or the yarn or fiber composition can exhibit a melting temperature(or melting point), Vicat softening temperature, heat deflectiontemperature, or a combination thereof, that is from about 80° C. toabout 135° C., or from about 90° C. to about 120° C. In one aspect, thethermoplastic material and/or the yarn or fiber composition can exhibita melting temperature, Vicat softening temperature, heat deflectiontemperature, or a combination thereof, that is about 135° C. or less,about 125° C. or less, or about 120° C. or less. In the same oralternative aspects, the article 14 can include one or more materialsthat will not melt or deform under the processing conditions disclosedherein. In such an aspect, in the case of such a thermoplastic material,such material can exhibit a melting temperature greater than about 135°C., greater than about 140° C., or greater than about 150° C. Further,in such aspects, another material that may be present in the article,such as a material other than a thermoplastic material, may not degradebelow a temperature of about 150° C., about 140° C., or about 135° C.

Using the system 10 and the method 160, the element 12 can be attachedto the article 14 without the need for high temperature heat lamps. Theheat lamps may limit the types of applications, materials and componentsthat may be coupled together. Moreover, the system 10 and method 160 mayreduce the labor required to efficiently couple elements 12 to articles14. It has also been found that the system 10 and the method 160 resultin a higher consistency of bonding quality and performance.

While specific reference in FIG. 13 is made to one or more steps, it iscontemplated that one or more additional or alternative steps may beimplemented while achieving aspects provided herein. As such, blocks maybe added or omitted while still staying within the scope hereof.

FIGS. 14-25 depict another aspect of a system 200 for providing heat toan article 214 (as seen in FIG. 23 ). In some aspects, the system 200,like the system 10, can be used to thermo-couple or attach an element212 to an article 214 (as best seen in FIG. 23 ). In some aspects, thearticle 214 is a portion of an article of footwear, such as an outsole.It should be understood, that while the system 200 depicts the article214 as a portion of an article of footwear, e.g., a sole assembly or anoutsole, other types of articles or other portions of an article offootwear can be utilized in the system 200 described herein. In someaspects, the article 214 may be constructed from thermo-fuse-ablematerials, having a desired melting temperature. In some aspects, theelement 212 is an accompanying part of an article of footwear, and insome aspects is a cleat plate. It should be understood that element 212could be any of a number of different elements coupled to the article214, e.g. a midsole, an outsole, aesthetic embellishments, a toesupport, a foxing strip or other footwear elements. In some aspects, thearticle 214 and/or the element 212 are of a thermoformable orthermoplastic material, or have a layer of thermoformable or thermallyactivated material thereon, that, when heated, forms the article 214into a desired three-dimensional shape and/or bonds or attaches thearticle 214 and the element 212 to one another.

In some aspects, the system 200 has an outer supportive frame 216. Insome aspects, the frame 216 is made from square metal tubing, but couldalso be any of a number of rigid materials. The frame 216 can besupported on a surface with a plurality of feet 218. As best seen inFIG. 15 , the frame includes a lower portion 220 and an upper portion222, separated by a plate 224. The lower portion 220 houses a vacuumtank (not shown). The frame 216, in some aspects, can be enclosed withouter guard panels 226 to prevent access to the internal components ofthe system 200. In the figures, some of the guard panels 226 are notshown to more clearly depict other aspects of the system 200.

As best seen in FIGS. 15 and 22 , the plate 224 supports an articlecontainer 228 that is in fluid communication with the vacuum tank, suchas through a port 230. In some aspects, the article container 228includes a jig 232 that supports a form 234 onto which the article 214and element 212 may be held. In some aspects, the jig 232 and the form234 are integrally formed. In other aspects, the sub-assembly of theform 234, the article 214 and the element 212 are loaded onto the jig232 in the article container 228 by an operator (shown schematically inFIG. 14 ).

As best seen in FIG. 22 , a media container 236 is coupled to a motor238 that is operable to move the media container 228 from an unloadingposition (as shown in FIGS. 18 and 22 ) to a heating position (shown inFIG. 16 , for example). The media container 236 includes a flexiblemembrane 240 held in place within a lower frame 242 of the mediacontainer 236. The media container further includes a perimeter wall 244that extends away from the frame 242 and the membrane 240. The perimeterwall 244 defines a chamber 246 above the membrane 240. In some aspects,the media container further includes a top 248 coupled to the wall 244.The top 248 may have a first opening 250 and a second opening 252(partially shown in FIG. 22 ).

The system 200 further includes a heated media chamber 254 that issupported on the frame 216. In some aspects, the chamber 254 issupported higher on the frame 216 than the media container 236. As shownin FIG. 14 , in some aspects the chamber 254 is circular in shape, butother shapes and sizes of the chamber 254 are contemplated herein. Asbest seen in FIG. 21 , the media chamber 254 holds a volume of formablemedia 256. In some aspects, the media 256 is sand, but it should beunderstood that other formable media having thermal retention propertiescould also be used, such as ceramic microspheres, glass microspheres,corundum or other materials. The media chamber 254, in some aspects,includes a number of heating elements 258 spaced throughout the mediachamber 254. In some aspects, the heating elements 258 are resistorsthat heat the formable media 256 to a constant temperature. Othermethods of heating the formable media 256 within the chamber 254 couldalso be used. In some aspects, a number of blades 260 extend into themedia chamber 254 which are coupled to a motor 262. The motor 262provides power to rotate the blades 260. As the blades rotate, theformable media 256 is redistributed within the chamber 254 to mix theformable media 256 in and around the heating elements 258 to provide theformable media 256 with a more uniform temperature distribution. Otheraspects of moving the formable media 256 within the chamber 254 are alsocontemplated, such as rotating an internal volume within the chamber254, or rotating an arm about the central shaft of the motor 262. Asbest seen in FIG. 24 , the chamber 254 includes an access door 264 thatis movably coupled to the top of the chamber 254. The access door 264 isoperably coupled to a piston 266. In a first position, the access door264 is closed, shown, for example, in FIG. 15 . In a second position,the access door 264 is pivoted open by the piston 266 about a hinge 267.The piston 266 is operable to move the access door 264 from the first,closed position to the second, open position, to allow access to theinternal cavity of the media chamber 254.

As best seen in FIG. 25 , the media chamber 254 also includes an exitport 268 in the bottom of the media chamber 254. In some aspects, theexit port 268 is a cylindrical opening that is connected to a hot sandduct 270. The exit port allows the formable media 256 in chamber 254 toflow into the hot sand duct 270. Access from the chamber 254 to the hotsand duct 270 is controlled by a door 272. The door 272 is coupled to apiston 274. The piston 274 is operable to position the door 272 to aclosed position covering the exit port 268, or to an open position awayfrom the exit port 268. In the open position, the formable media 256 inchamber 254 can flow (via gravitational forces) into the hot sand duct270. As best seen in FIG. 15 , the hot sand duct 270 is coupled to anexit duct 276. In some aspects, the exit duct 276 is pivotable between astowed position, as seen in FIG. 14 , for example, and a loadingposition, as seen in FIG. 17 , for example, via a motor 278 and junctionbox 280. In some aspects, the motor 278 is held in place and supportedon the frame 216.

The system 200, in some aspects, further includes a return bucket 282,as best seen in FIG. 14 . The return bucket 282 may have a front wall284 having a u-shaped opening formed therein. The return bucket 282 issupported on a platform having a rack gear (not shown) that mates withan elongated worm gear 286. The worm gear 286 extends from the plate 224and upward to a driven gear or pulley 288. The driven gear 288 iscoupled to a drive gear 290 which is driven by a motor (not shown)within a housing 292. As the motor drives gear 290 and gear 288, theworm gear 286 rotates and interacts with the rack to selectively movethe platform and the return bucket 282 from a lower position (as shownin FIG. 18 , for example) to a raised position (as shown in FIG. 19 ,for example). The return bucket 282 is also coupled to a dump motor 294,as seen in FIG. 14 . The dump motor 294 is operable to move the returnbucket from the loaded position shown in FIG. 19 , for example, to theunloading position shown in FIG. 20 , for example. As seen in FIG. 14 ,the operation of the system 200 may be controlled at an operator station296 that controls the operation and sequencing of the various motors andpistons described above.

In use, an operator may load the article 214 and the element 212 withinthe system 200, such as by placing the article 214 and the element 212in place on the form 234 and/or the jig 232. In this initial step, themedia container 236 is pivoted to the open position by motor 238 toallow access to the jig 232. Also in this initial step, the door 276 ispositioned over the exit port 268, the exit duct 276 is in the stowedposition and the return bucket 282 is in the lowered position.

With the article 214 and element 212 in place (such as is shown in FIG.23 ), the media container 236 is pivoted into the lowered position bymotor 238, as shown in FIG. 16 . In this position, the membrane 240deforms around the adjacent element 212 and article 214. When in thisposition, a vacuum is applied, through port 230, pulling the membrane240 tighter against the adjacent element 212 and article 214. The motor278 is then engaged to rotate the exit duct 276 to the loading positionshown in FIG. 17 . In this position, the terminal end of the exit duct276 is aligned with the first opening 250 in the top 248 of the mediacontainer 236. In this position, the hot sand duct 270 and the exit duct276 are aligned to deliver the heated formable media 256 from the mediachamber 254 to the media container 236. To release the formable media256, the piston 274 is engaged to move the door 272 away from the exitport 268, allowing the heated formable media 256 to move, via gravity,from the media chamber 254 to the media container 236. The amount ofmedia 256 is metered by the length of time the door 272 remains awayfrom the exit port 268. As with the system 10 described above, theheated formable media 256 is left in place in the media container 236 inengagement with the membrane 240 for a time sufficient to fuse, bond orotherwise attach through heating, the article 214 and the element 212.After this time delay, the exit duct 276 is rotated to the stowedposition by the motor 278, and the media container 236 is rotated by themotor 238 to dump the formable media 256 from the media container 236into the return bucket 282, as shown in FIG. 18 . In some aspects, theformable media 256 exits the media container 236 via the second opening252. As shown in FIG. 18 , the u-shaped front wall of the return bucket282 allows overlap of the media container 236 and the return bucket 282.With the media container 236 in this position, the operator may removethe now coupled assembly of the article 214 and the element 212. At thispoint, the motor within the housing 292 engages the drive gear 290 torotate the worm gear 286, elevating the return bucket 282 to the raisedposition shown in FIG. 19 . Once the return bucket 282 is in the raisedposition, the piston 266 is engaged to move access door 264, allowingaccess to the internal volume of media chamber 254. With the access door264 open, the motor 294 is engaged to rotate the return bucket 282,returning the formable media 256 to the media chamber 254 to be reheated(as shown in FIG. 20 ). The return bucket 282 is then lowered, and theprocess can begin again.

FIG. 26 depicts another aspect of a system 300 for providing heat to anarticle. In some aspects, the system 300, like the system 10 and thesystem 200, can be used to thermo-couple or attach an element to anarticle. The system 300 is similar in many respects to the system 200described above with reference to FIGS. 14-25 . To that end, similarcomponents are labeled with the same reference numbers from FIGS. 14-25. One difference in system 300 from system 200 relates to a returnassembly 302 that replaces the return bucket 282 and the drive system ofthe worm gear 286, the driven gear 288 and the drive gear 290, alongwith the dump motor 294. In some aspects, the return assembly 302includes a hopper 304 that receives formable media 256 as the mediacontainer 236 is pivoted away from the article container 228 by themotor 238. An auger 306 is powered by a motor (not shown). The auger 306extends from the hopper 304 to the heated media chamber 254. As themotor turns the auger 306, formable media 256 within the hopper 304 isreturned to the heated media chamber 254. In some aspects, the heatedmedia chamber 254 of system 300 may have a return chute 308 to guide theformable media 256 into the media chamber 254.

FIGS. 27 and 28 depict yet another aspect of a system 400 for providingheat to an article. In some aspects, the system 400, like the system 10,the system 200, and the system 300, can be used to thermo-couple orattach an element to an article. The system 400 is similar in manyrespects to the system 200 described above with reference to FIGS. 14-25. To that end, similar components are labeled with the same referencenumbers from FIGS. 14-25 . System 400 differs from system 200 in thatthe system 400 is a rotary system with a platform 402 having multiplestations 404 positioned thereon, allowing multiple article and elementassemblies to be in process at one time. In some aspects, each station404 includes the article container 228 and media container 236 (asdescribed above). FIG. 27 schematically depicts an operator 406 usingthe system 400. As with system 200, the operator 406 may place anarticle and element assembly within the article container 228 at a firstposition 408. In the first position 408, the media container 236 ispivoted away from the article container 228, allowing the operator 406to place the article and element assembly into the article container228. The operator 406 can interact with a control panel 296 to indicatethe article and element are in place within the article container 228.As best seen in FIG. 28 , with the article and element assembly inplace, the media container 236 is rotated down and into place over thearticle container 228. For clarity, the basic components of system 400are shown somewhat schematically. With the media container 236 in placeover the article container 228, a vacuum is applied to the membrane 240(not shown) as described above with respect to FIGS. 14-25 . The system400 then rotates (in one aspect via a motor below the platform 402) theplatform 402 such that the station 404 is positioned below the hot sandduct 270, as indicated at a second position 410. When the station 404 isat the second position 410, heated formable media 256 is routed throughthe hot sand duct 270 from the heated media chamber 254. The platform402 is then rotated again. When the station 404 is at positions labeled412, 414 and 416, the heated formable media 256 transfers heat to thearticle and element to fuse or attach them together. The return bucket282 is at a position labeled 418. As described above with respect toFIGS. 14-25 , the media container 236 can be pivoted to dump theformable media 256 into the return bucket 282, which in turn, iselevated and dumped to return the formable media 256 to the heated mediachamber 254. As the station 404 returns to the position 408, theoperator 406 can remove the now coupled article and element, and placeanother article and element within the article container 228 forprocessing. Using the system 400, a number of article and elementassemblies can be in process at the same time.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

While specific elements and steps are discussed in connection to oneanother, it is understood that any element and/or steps provided hereinis contemplated as being combinable with any other elements and/or stepsregardless of explicit provision of the same while still being withinthe scope provided herein. Since many possible embodiments may be madeof the disclosure without departing from the scope thereof, it is to beunderstood that all matter herein set forth or shown in the accompanyingdrawings is to be interpreted as illustrative and not in a limitingsense.

Some aspects of this disclosure have been described with respect to theexamples provided in the figures. Additional aspects of the disclosurewill now be described that may be related subject matter included in oneor more claims or clauses of this application at the time of filing, orone or more related applications, but the claims or clauses are notlimited to only the subject matter described in the below portions ofthis description. These additional aspects may include featuresillustrated by the figures, features not illustrated by the figures, andany combination thereof. When describing these additional aspects,reference may be made to elements depicted by the figures forillustrative purposes.

As used herein and in connection with the claims listed hereinafter, theterminology “any of clauses” or similar variations of said terminologyis intended to be interpreted such that features of claims/clauses maybe combined in any combination. For example, an exemplary clause 4 mayindicate the method/apparatus of any of clauses 1 through 3, which isintended to be interpreted such that features of clause 1 and clause 4may be combined, elements of clause 2 and clause 4 may be combined,elements of clause 3 and 4 may be combined, elements of clauses 1, 2,and 4 may be combined, elements of clauses 2, 3, and 4 may be combined,elements of clauses 1, 2, 3, and 4 may be combined, and/or othervariations. Further, the terminology “any of clauses” or similarvariations of said terminology is intended to include “any one ofclauses” or other variations of such terminology, as indicated by someof the examples provided above.

The following clauses are aspects contemplated herein.

Clause 1. A method for attaching an element to an article, the methodcomprising: inserting at least a portion of the article over a form;placing the element on the article in a desired location; inserting theform, article and element at least partially within an articlecontainer; moving the form, article and element into engagement with aflexible membrane, the membrane and the article container forming anairtight chamber; exposing the airtight chamber to a pressure less thanatmospheric pressure to pull the membrane against at least a portion ofthe article and the element; and exposing the membrane to a heateddeformable media.

Clause 2. The method according to clause 1, wherein the articlecomprises a portion of an article of footwear.

Clause 3. The method according to any of clauses 1-2, wherein theportion of an article of footwear comprises an upper.

Clause 4. The method according to any of clauses 1-3, wherein the formcomprises a last.

Clause 5. The method according to any of clauses 1-4, wherein thedeformable media is sand.

Clause 6. The method according to any of clauses 1-5, wherein theflexible membrane forms a portion of a media container having a firstchamber and a second chamber, and wherein the flexible membrane formsthe bottom of the second chamber, the method further comprising heatingthe deformable media in the first chamber prior to exposing the membraneto the heated deformable media.

Clause 7. The method according to any of clauses 1-6, wherein theexposing the membrane to the deformable media comprises allowing theheated deformable media to flow from the first chamber of the mediacontainer to the second chamber of the media container.

Clause 8. The method according to any of clauses 1-7, further comprisingexposing the membrane to the heated deformable media for a predeterminedperiod of time.

Clause 9. The method according to any of clauses 1-8, furthercomprising, following the exposing the membrane to the heated deformablemedia, upending the media container such that the first chamber is onthe bottom and the second chamber is on the top to allow the deformablemedia to return to the first chamber.

Clause 10. A system for providing heat to a three-dimensional article,the system comprising: an article container having an interior volume,the article container having at least one open face; a form selectivelyheld at least partially within the article container, the form having ashape at least partially corresponding to the three-dimensional article,and adapted to hold the three-dimensional article; a media containerhaving a first chamber and a second chamber, the first chamber and thesecond chamber separated by a selectively openable valve; a flexiblemembrane extending at least partially across a face of the secondchamber of the media container; a deformable media held within the mediacontainer, the deformable media being held within the first chamber in afirst condition when the selectively openable valve is in a closedposition, and the deformable media being allowed to enter the secondchamber when the selectively openable valve is in an open position; atleast one heating element positioned to heat the deformable media whenthe deformable media is in the first chamber of the media container; anengagement mechanism coupled to the article container and adapted tomove the article container such that the form is moved into engagementwith the flexible membrane on the media container; and wherein thedeformable media can be heated by the at least one heating element whenthe deformable media is in the first chamber and wherein the heateddeformable media is allowed to enter the second chamber by opening theselectively openable valve, wherein the deformable media surrounds theflexible membrane.

Clause 11. The system according to clause 10, wherein thethree-dimensional article is a footwear upper.

Clause 12. The system according to any of clauses 10-11, wherein thedeformable media is sand.

Clause 13. The system according to any of clauses 10-12, furthercomprising a vacuum coupled to the article container, and wherein anegative pressure can be applied by the vacuum when the articlecontainer is engaged with the flexible membrane of the media container.

Clause 14. The system according to any of clauses 10-13, furthercomprising a plurality of heating elements, wherein the heating elementsextend across and through the first chamber of the media container.

Clause 15. The system according to any of clauses 10-14, furthercomprising an actuator coupled to the article container, the actuatoradapted to move the article container from a loading position distalfrom the media container to a forward position in alignment with themedia container.

Clause 16. The system according to any of clauses 10-15, furthercomprising a motor coupled to the media container, the motor operable torotate the media container from a first position wherein the firstchamber is above the second chamber and a second position wherein thefirst chamber is below the second chamber.

Clause 17. A method for providing heat to an article is provided. Themethod can include inserting at least a portion of the article over aform. The method can further include inserting the form and article atleast partially within an article container and moving into engagementthe form and article and the flexible membrane. The method can furtherinclude exposing the membrane to a heated deformable media.

Clause 18. The method according to clause 17, wherein the moving theform and article into engagement with the flexible membrane forms anairtight chamber between the article container and the flexiblemembrane, further comprising exposing the airtight chamber to a pressureless than atmospheric pressure to pull the membrane against at least aportion of the article before the exposing the membrane to the heateddeformable media.

Clause 19. The method according to any of clauses 17-18, furthercomprising heating the deformable media with at least one heatingelement prior to the exposing the membrane to the heated deformablemedia.

Clause 20. The method according to any of clauses 17-19, wherein thearticle comprises a portion of an article of footwear.

Clause 21. A system for providing heat to a three-dimensional article,the system comprising: an article container having an interior volume,the article container having at least one open face; a form selectivelyheld at least partially within the article container, the form having ashape at least partially corresponding to the three-dimensional article,and adapted to hold the three-dimensional article; a media containerpivotal with respect to the article container between an open positionallowing access to the interior volume of the article container, and aclosed position with the media container over the article container; aflexible membrane extending at least partially across the mediacontainer, the membrane covering the open face of the article containerwhen the media container is in the closed position; a media chamberhaving at least one heating element and a selectively openable door; atleast one duct between the media chamber and the media container, theduct providing access between the media chamber and the media containerwhen the selectively openable door is in an open condition; a deformablemedia held within the media chamber for heating by the heating elements,the deformable media being held within the media chamber when theselectively openable door is in a closed position, and the deformablemedia being allowed to enter the duct and transferred to the mediacontainer when the selectively openable door is in an open position; andwherein the deformable media can be heated when the deformable media isin the media chamber and wherein the heated deformable media is allowedto enter the duct by opening the selectively openable door, wherein thedeformable media is allowed to flow into the media container above themembrane.

Clause 22. The system according to clause 21, wherein thethree-dimensional article is a footwear outsole.

Clause 23. The system according to any of clauses 21-22, wherein thedeformable media is sand.

Clause 24. The system according to any of clauses 21-23, furthercomprising a vacuum coupled to the article container, and wherein anegative pressure can be applied by the vacuum when the articlecontainer is engaged with the flexible membrane of the media container.

Clause 25. The system according to any of clauses 21-24, furthercomprising a plurality of heating elements within the media chamber.

Clause 26. The system according to any of clauses 21-25, furthercomprising a motor coupled to the media container, the motor adapted tomove the media container from the open position away from the articlecontainer to the closed position over the article container.

Clause 27. The system according to any of clauses 21-26, furthercomprising a return bucket moveable from a location adjacent the mediacontainer to a location adjacent the media chamber, the return bucketmoveable to return the deformable media to the media chamber.

Clause 28. The system according to any of clauses 21-27, furthercomprising a hopper adjacent the media container and an auger extendingfrom the hopper to the media chamber, the auger operable to return thedeformable media from the hopper to the media chamber.

Clause 29. The system according to any of clauses 21-28, furthercomprising a rotatable platform supporting multiple stations, eachstation having an article container and a media container.

The invention claimed is:
 1. A system for providing heat to athree-dimensional article, the system comprising: an article containerhaving an interior volume, the article container having at least oneopen face; a form selectively held at least partially within the articlecontainer, the form having a shape at least partially corresponding tothe three-dimensional article, and adapted to hold the three-dimensionalarticle; a media container having a first chamber and a second chamberthe first chamber and the second chamber separated by a selectivelyopenable valve; a flexible membrane extending at least partially acrossa face of the second chamber of the media container; a deformable mediaheld within the media container, the deformable media being held withinthe first chamber in a first condition when the selectively openablevalve is in a closed position, and the deformable media being allowed toenter the second chamber when the selectively openable valve is in anopen position; at least one heating element positioned to heat thedeformable media when the deformable media is in the first chamber ofthe media container; an engagement mechanism coupled to the articlecontainer and adapted to move the article container such that the formis moved into engagement with the flexible membrane on the mediacontainer; and wherein the deformable media can be heated by the atleast one heating element when the deformable media is in the firstchamber and wherein the heated deformable media is allowed to enter thesecond chamber by opening the selectively openable valve, wherein thedeformable media surrounds the flexible membrane.
 2. The systemaccording to claim 1, wherein the three-dimensional article is afootwear upper.
 3. The system according to claim 1, wherein thedeformable media is sand.
 4. The system according to claim 1, furthercomprising a vacuum coupled to the article container, and wherein anegative pressure can be applied by the vacuum when the articlecontainer is engaged with the flexible membrane of the media container.5. The system according to claim 1, further comprising a plurality ofheating elements, wherein the heating elements extend across and throughthe first chamber of the media container.
 6. The system according toclaim 1, further comprising an actuator coupled to the articlecontainer, the actuator adapted to move the article container from aloading position distal from the media container to a forward positionin alignment with the media container.
 7. The system according to claim1, further comprising a motor coupled to the media container, the motoroperable to rotate the media container from a first position wherein thefirst chamber is above the second chamber and a second position whereinthe first chamber is below the second chamber.
 8. A system for providingheat to a three-dimensional article, the system comprising: an articlecontainer having an interior volume, the article container having atleast one open face; a form selectively held at least partially withinthe article container, the form having a shape at least partiallycorresponding to the three-dimensional article, and adapted to hold thethree-dimensional article; a media container pivotal with respect to thearticle container between an open position allowing access to theinterior volume of the article container, and a closed position with themedia container over the article container; a flexible membraneextending at least partially across the media container, the membranecovering the open face of the article container when the media containeris in the closed position; a media chamber having at least one heatingelement and a selectively openable door; at least one duct between themedia chamber and the media container, the duct providing access betweenthe media chamber and the media container when the selectively openabledoor is in an open condition; a deformable media held within the mediachamber for heating by the at least one heating element, the deformablemedia being held within the media chamber when the selectively openabledoor is in a closed position, and the deformable media being allowed toenter the duct and transferred to the media container when theselectively openable door is in an open position; and wherein thedeformable media can be heated when the deformable media is in the mediachamber and wherein the heated deformable media is allowed to enter theduct by opening the selectively openable door, wherein the deformablemedia is allowed to flow into the media container above the membrane. 9.The system according to claim 8, wherein the three-dimensional articleis a footwear outsole.
 10. The system according to claim 8, wherein thedeformable media is sand.
 11. The system according to claim 8, furthercomprising a vacuum coupled to the article container, and wherein anegative pressure can be applied by the vacuum when the articlecontainer is engaged with the flexible membrane of the media container.12. The system according to claim 8, further comprising a plurality ofheating elements within the media chamber.
 13. The system according toclaim 8, further comprising a motor coupled to the media container, themotor adapted to move the media container from the open position awayfrom the article container to the closed position over the articlecontainer.
 14. The system according to claim 8, further comprising areturn bucket moveable from a location adjacent the media container to alocation adjacent the media chamber, the return bucket moveable toreturn the deformable media to the media chamber.
 15. The systemaccording to claim 8, further comprising a hopper adjacent the mediacontainer and an auger extending from the hopper to the media chamber,the auger operable to return the deformable media from the hopper to themedia chamber.
 16. The system according to claim 8, further comprising arotatable platform supporting multiple stations, each station having anarticle container and a media container.